Roof vent for a corrugated metal roof

ABSTRACT

A roof vent comprising a vent base and a vent top. The vent base broadly includes a frame, an upper flashing, a lower flashing, a left flashing, and a right flashing. The frame includes a lip for attaching the vent top to the vent base. The lower flashing is configured to define an open-ended cavity. The vent base structure prevents rainwater from pooling above the roof vent and diverts rainwater around the roof vent and into the troughs of a corrugated metal roof surface. A sealant material is placed beneath the vent base where it is protected. The upper flashing may include a left vertical wall, a right vertical wall, a left flange, and a right flange configured to divert rainwater over the raised ridges of the corrugated metal roof surface. The vent top is attached to the vent base and includes a collar flashing, a collar, and a cap.

FIELD OF INVENTION

Embodiments of the present invention relate generally to the field of roof flashings that function to prevent rainwater and debris from entering an opening in a metal roof surface and building vent systems that function to exhaust indoor air and moisture out of a building.

BACKGROUND

Roof vents are commonly installed on building roof surfaces. The installation of a conventional roof vent on a metal roof typically requires two or more workers to detach and lift a pre-installed metal roof panel while standing on a ladder or on the roof surface. The workers install the vent base flashing by sliding it beneath the raised metal roof panel until an aperture in the flashing is directly over a roof opening or the aperture surrounds a roof penetration, e.g., a pipe or other protruding structure. The raised metal roof panel is then lowered back into place, reattached to the roof surface, and a vent cap is mounted on top of the vent base flashing. A worker then caulks each of the exposed joints located between the vent base flashing, the vent cap, and the metal roof panel to make the installed roof vent watertight.

The installation of a conventional roof vent in a metal roof presents a number of problems. For example, detaching and raising a pre-installed metal roof panel is time consuming and dangerous for workers, especially on windy days. Also, the exposed caulked joints are exposed to the sunlight, moisture, debris, and other elements. Over time, the caulking material becomes brittle, cracks, peels, or rots away. For example, as rainwater flows down a corrugated metal roof surface, it becomes trapped in the troughs located above the roof vent. These trapped pools of water degrade the exposed caulking material, corrode the vent and metal roofing material, and cause the vent to eventually leak water into the building. In cold climates, the repeated freezing and thawing of these trapped pools of water accelerates damage to the caulking material and compromises the integrity of the vent and metal roofing materials.

SUMMARY

An improved roof vent for a corrugated metal roof that overcomes the above problems is provided. A first embodiment of the invention is a roof vent that broadly comprises a vent base and a vent top. The vent base includes a frame, an upper flashing, a lower flashing, a left flashing, and a right flashing. The frame includes a number of side walls that cooperatively define an aperture that surrounds a roof opening or penetration. A lip for attaching the vent top to the vent base extends outwardly from the side walls of the frame. The lower flashing includes a covering member and lateral side walls that extend downwardly to define an open-ended cavity beneath the lower flashing. The vent base is installed by inserting the upper flashing into a pre-cut slot in a corrugated metal roof panel and sliding the upper flashing beneath the panel. Sealant material is placed beneath the lower surfaces of the vent base where it is protected from sunlight, moisture, and debris. The vent top mounts to the lip of the frame and includes a cap flashing, a collar, and a cap.

In another embodiment, the upper flashing may further include a left vertical wall, a right vertical wall, a left flange, and a right flange, which may extend above and over the raised ridges of the corrugated metal roof surface. During a heavy rainfall, these structures divert water up and over the raised ridges of the roof surface and around the vent base.

The present invention has many advantages over the prior art. The roof vent is safely installed without detaching and lifting a corrugated metal roof panel, which saves time and improves worker safety. The roof vent has no exposed caulked joints, which eliminates the need to periodically re-apply or replace damaged caulking material. Moreover, due to the unique vent base structure, rainwater is not trapped between the raised ridges of the corrugated metal roof and does not pool above the roof vent. Instead, rainwater flows down the metal roof surface to the roof vent where it is diverted around both sides of the vent base and flows down the roof surface.

This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description below. The summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a perspective view of an installed roof vent, constructed in accordance with an embodiment of the present invention;

FIG. 2 is a side view of the vent base of the roof vent of FIG. 1, constructed in accordance with an embodiment of the present invention;

FIG. 3 is a top plan view of the vent base of the roof vent of FIG. 1, constructed in accordance with an embodiment of the present invention;

FIG. 4 is a bottom plan view of the vent base of the roof vent of FIG. 1, constructed in accordance with an embodiment of the present invention;

FIGS. 5a and 5b are perspective views showing the successive steps of installing the roof vent of FIG. 1, constructed in accordance with an embodiment of the present invention; and

FIG. 6 is a side elevational view of the roof vent, constructed in accordance with another embodiment of the present invention.

The drawing figures do not limit the current invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The following detailed description of the invention references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the current invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the current invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.

In this description, references to “one embodiment”, “an embodiment”, or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment”, “an embodiment”, or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the current technology can include a variety of combinations and/or integrations of the embodiments described herein.

Turning to FIGS. 1-6, a roof vent 10 constructed in accordance with an embodiment of the present invention is illustrated. The roof vent 10 broadly includes a vent base 12 and a vent top 14. The vent base 12 and vent top 14 may be formed of plastic, metal, composite, or any other suitable durable material or combination of durable materials.

The vent base 12 is installed around an opening or penetration in a corrugated metal roof and broadly comprises a frame 16, an upper flashing 18, a lower flashing 20, a left flashing 22, and a right flashing 24. The vent base 12 components may be fastened or welded together or unitarily formed out of a single piece of material. The frame 16 includes a right side wall 26, a left side wall 28, a top side wall 30, and a bottom side wall 32. The heights, lengths, and widths of the right side wall 26, the left side wall 28, the top side wall 30, and the bottom side wall 32 may vary. For example, in one embodiment, the top side wall 30 has a length that is greater than the length of the bottom side wall 32. The frame's 16 side walls 26, 28, 30, 32 cooperatively form an aperture 34 that surrounds a penetration or a pre-cut opening in the corrugated metal roof surface. The upper edges of the side walls 26, 28, 30, 32 may have a lip 36 that extends outwardly for attaching the vent top 14 to the vent base 12.

As explained in more detail below, a sealant material 38 may be installed in various locations beneath the vent base 12 to make it watertight and to prevent insects and debris from entering the roof opening. For example, during installation, the sealant material 38 may be placed beneath the right side wall 26 and the left side wall 28. The right side wall 26 and the left side wall 28 cover and protect the sealant material 38 from exposure to sunlight, moisture, and other elements. The sealant material 38 may be a close-celled foam tape, caulk, weather-stripping or any other suitable waterproof and weather-resistant material. In one embodiment, the sealant material 38 may be Uline® double-sided adhesive foam tape. In another embodiment, the sealant material 38 may be butyl tape made by GSSI Sealants, Inc.

The upper flashing 18 of the vent base 12 is a generally flat planer member that extends outwardly from the top side wall 30 of the frame 16. The upper flashing 18 broadly includes a distal edge 40, a proximal edge 42, a left edge 44, and a right edge 46. When installed, the distal edge 40 is positioned beneath the installed metal roof material with a portion of the left edge 44 and right edge 46 nearest the frame 16 exposed and positioned in the corrugated metal roof troughs located on the either side of the vent base 12. The width the upper flashing 18 may vary, i.e., it may be the same width as the frame, wider than the frame, or narrower than the frame, depending on the corrugation pattern of the metal roof surface. When it rains, water flows down the corrugated metal roof surface to the top side wall 30 where it is diverted around the left edge 44 and right edge 46 of the upper flashing 18 and flows into the roof troughs located on both sides of the vent base 12.

The lower flashing 20 extends outwardly from the bottom side wall 32 and spans above and across one or more raised ridges of the corrugated metal roof surface. The lower flashing 20 broadly includes a covering member 48, a left lateral wall 50, and a right lateral wall 52. The left lateral wall 50 and the right lateral wall 52 extend downwardly from the opposite side edges of the covering member 48 and rest in parallel troughs. The covering member 48, left lateral wall 50, and right lateral wall 52 together define an open-ended cavity 54 beneath the lower flashing 20. During installation, a sealant material 38 is placed beneath the covering member 48 and across the open-ended cavity 54. The sealant material 38 prevents water, insects, and debris from entering the frame 16 through the open-ended cavity 54. The lower flashing 20 covers and protects the sealant material 38 from exposure to sunlight, moisture, and other elements.

The left flashing 22 extends outwardly from the bottom edge of the left side wall 28 of the frame 16 and the bottom edge of the left lateral wall 50 of the lower flashing 20. Likewise, the right flashing 24 extends outwardly from the bottom edge of the right side wall 26 of the frame 16 and the bottom edge of the right lateral wall 52 of the lower flashing 20. The left flashing 22 and the right flashing 24 rest in parallel troughs of the corrugated metal roof surface. The sealant material 38 may be placed beneath the lower surface of the left flashing 22 and the right flashing 24 to make the sides of the vent base 12 watertight. The vent base 12 may be anchored to the corrugated metal roof surface by inserting roofing nails, screws, or any other suitable roofing fasteners 62 through the left flashing 22 and the right flashing 24 and into the roof surface.

The vent top 14 broadly includes a collar flashing 56, a collar 58, and a cap 60. It will be understood that the collar flashing 56, collar 58, and cap 60 may be joined together by fasteners, welding, adhesives, or any other suitable material, or may be unitarily formed out of a single piece of material. The collar 58 and the cap 60 may include one or more exit apertures 34. Rising indoor gases and moisture from the building escape through the exit apertures 34. The collar flashing 56 covers the frame 16 to prevent water and debris from entering a penetration or opening in the roof. Several methods or combinations of methods may be used to join the cap flashing 56 to the lip 36 of the frame 16. For example, in one embodiment, two or more fasteners 62 may be used to secure the collar flashing 56 to the lip 36. In another embodiment, as best shown in FIG. 6, the vent cap may be secured to the vent base 12 by bending the edge of the collar flashing 56 around the lip 36 of one or more side walls 26, 28, 30, 32.

The collar 58 structurally supports the cap 60 above the collar flashing 56. The bottom of the collar 58 is coupled to the collar flashing 56, and the top of the collar 58 supports the cap. The length and shape of the collar 58 may vary. For example, the collar 58 may be cylindrical, square, or any other suitable shape. Various styles of caps 60 may be used depending on the shape of the collar 58, type of building structure, roof pitch, type of corrugated metal roofing material used, personal preferences, and other considerations. For example, as shown in FIG. 1, the cap 60 may be a turbine style. In another embodiment, as shown in FIG. 6, the cap 60 may be an aura style. The cap 60 may be removably connected to the top of the collar 58 (as shown in FIG. 5B) or may be integrally formed with the collar 58.

Turning now to FIGS. 5a and 5b , installation of the roof vent 10 will now be described in more detail. First, the surface of the pre-installed corrugated metal roof is prepared. Above the opening or penetration in the roof surface, a slot is cut through the corrugated roofing material to receive the distal edge 40 of the upper flashing 18. The pre-cut slot runs perpendicular to the raised ridges and troughs of the roof and has a length that is approximately the same as the width of the upper flashing 18. Below the opening or penetration in the roof surface, a sealant material 38 is placed across the roof surface. The sealant material 38 runs perpendicular to the raised ridges of the roof and seals the open-ended cavity 54 located beneath the lower flashing 20.

Second, the vent base 12 is installed. A sealant material 38 is placed on the lower surfaces of the left side wall 28 and the right side wall 26. As best shown in FIGS. 1 and 5 a, the upper flashing 18 of the vent base 12 is installed by inserting the distal edge 40 of the upper flashing 18 into the pre-cut slot and sliding the upper flashing 18 beneath the corrugated metal roof material. The left edge 44 and right edge 46 of the upper flashing 18 nearest the frame 16 are exposed and positioned in the roof troughs located on the either side of the vent base 12. The bottom wall of the frame 16 is then positioned above the sealant material 38 that was previously placed across the roof surface below the opening or penetration in the roof surface. The sealant material 38 contacts the lower flashing 20, sealing the open-ended cavity 54. Fasteners 62 are inserted through the left flashing 22 and the right flashing 24 to secure the vent base 12 to the metal roof surface. Third, the vent top 14 is mounted on the vent base 12 by attaching the cap flashing 56 to the lip 36 of the frame 16 with fasteners 62, bending the edges of the cap flashing 56 around the lip of one or more sides walls 26, 28, 30, 32 of the frame 16, or a combination of these attachment methods.

The above-described roof vent 10 provides numerous advantages over the prior art. For example, the vent base 12 is installed without detaching and lifting an installed metal roof panel. This saves time, money, and improves worker safety. The present invention has no exposed caulked joints. The sealant material 38 is located beneath the vent base 12 where it is protected from sunlight, moisture, and debris. When it rains, water does not pool above the vent base 12 due to its unique structure. Instead, rainwater is quickly diverted around the vent base 12 and into troughs in the roof surface. Thus, corrosion of the roof vent 10 and the corrugated metal roof from trapped rainwater is obviated, prolonging the structural integrity of the roof vent 10 and corrugated roof.

Another embodiment of the present invention is a roof vent 10 that is similar to the above-described embodiments, wherein the upper flashing 18 is wider than the frame 16 width. The upper flashing 18 broadly includes a left vertical wall 64 and a right vertical wall 66. The left vertical wall 64 and the right vertical wall 66 extend upward from and are joined to opposite ends of the proximal edge 42 of the upper flashing 18. The left vertical wall 64 may be joined to the left side wall 28 of the frame 16. Correspondingly, the right vertical wall 66 may be joined to the right side wall 26 of the frame 16. The heights of the left vertical wall 64 and the right vertical wall 66 may exceed the height of the roof's raised ridges.

In another embodiment, the upper flashing 18 further includes a left flange 68 and a right flange 70. The left flange 68 extends outwardly from the left vertical wall 64 and may be spaced from or joined to the left side wall 28 of the frame 16. Similarly, a right flange 70 extends outwardly from the right vertical wall 66 and may be spaced from or joined to the right side wall 26 of the frame 16. The left flange 68 and the right flange 70 may extend over the raised ridges of the corrugated metal roof surface. During a heavy rainfall, the left vertical wall 64, the right vertical wall 66, the left flange 68, and the right flange 70 divert water up and over the raised ridges and down the metal roof surface thus, preventing water from pooling above the vent base 12.

Although the invention has been described with reference to the embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims. Having thus described various embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following: 

1. A roof vent comprising: a vent base comprising: a frame including a right side wall, a left side wall, a top side wall, and a bottom side wall; an upper flashing joined to and extending outwardly from the top side wall of the frame; a lower flashing including an elevated covering member, a left lateral wall, and a right lateral wall, wherein the elevated covering member spans above one or more ridges of a corrugated metal roof and is not seamed to the corrugated metal roof; an open-ended cavity that is formed when the vent base is installed on the corrugated metal roof and is defined by the left lateral wall, the right lateral wall, the elevated covering member, and the corrugated metal roof; a left flashing; and a right flashing; a vent top comprising: a collar flashing; a collar; and a cap.
 2. The roof vent of claim 1, wherein the frame includes an aperture.
 3. The roof vent of claim 1, wherein the frame includes a lip that extends outwardly from the upper edges of the right side wall, the left side wall, the top side wall, and the bottom side wall.
 4. The roof vent of claim 3, further comprising two or more fasteners for attaching the collar flashing to the lip.
 5. The roof vent of claim 3, wherein the collar flashing is malleable.
 6. The roof vent of claim 1, further comprising two or more fasteners for attaching the left flashing and the right flashing to the roof surface.
 7. The roof vent of claim 1, further comprising a sealant material placed beneath the vent base to make the vent base watertight.
 8. The roof vent of claim 7, wherein the sealant material is two strips of adhesive foam tape that are placed beneath the left side wall and the right side wall of the frame during installation of the roof vent.
 9. The roof vent of claim 8, wherein the sealant material is a strip of adhesive foam tape that is placed beneath the elevated covering member and across the open-ended cavity during installation of the roof vent.
 10. The roof vent of claim 1, wherein the upper flashing is a flat planer member that includes a distal edge, a proximal edge, a left edge, and a right edge.
 11. The roof vent of claim 10, wherein the distal edge is configured to be positioned beneath a corrugated metal root.
 12. The roof vent of claim 1, wherein the lower flashing extends outwardly from the bottom side wall.
 13. The roof vent of claim 1, wherein the left flashing extends outwardly from the bottom edge of the left side wall of the frame and outwardly from the bottom edge of the left lateral wall of the lower flashing.
 14. The roof vent of claim 1, wherein the right flashing extends outwardly from the bottom edge of the right side wall of the frame and outwardly from the bottom edge of the right lateral wall of the lower flashing.
 15. The roof vent of claim 10, wherein the upper flashing is wider than the frame width.
 16. The roof vent of claim 15, wherein the upper flashing further comprises a left vertical wall and a right vertical wall that extend above one or more raised ridges of a corrugated metal roof.
 17. The roof vent of claim 16, wherein the left vertical wall and the right vertical wall extend upward from and are joined to opposite ends of the proximal edge of the upper flashing.
 18. The roof vent of claim 17, wherein the upper flashing further comprises a left flange that extends outwardly from the left vertical wall and a right flange that extends outwardly from the right vertical wall.
 19. The roof vent of claim 18, wherein the left flange is joined to the left side wall of the frame and the right flange is joined to the right side all of the frame.
 20. A roof vent comprising: a vent base comprising: a frame including a right side wall, a left side wall, a top side wall, a bottom side wall, and a lip wherein the lip extends outwardly from the upper edges of the right side wall, the left side wall, the top side wall, and the bottom side wall; an upper flashing including a left vertical wall a right vertical wall, a left flange and a right flange wherein the left vertical wall, the right vertical wall, the left flange and the right flange are configured to divert water up and over one or more raised ridges of a corrugated metal roof surface; a lower flashing including an elevated covering member, a left lateral wall, and a right lateral wall, wherein the elevated covering member spans above one or more ridges of a corrugated metal roof and is not seamed to the corrugated metal roof; an open-ended cavity that is formed when the vent base is installed on the corrugated metal root and is defined by the left lateral wall, the right lateral wall, the elevated covering member, and the corrugated metal roof; a left flashing; and a right flashing; a vent top comprising: a collar flashing; a collar; and a cap. 